Powder Metallurgy Processes With Heating Or Sintering Patents (Class 419/1)
  • Patent number: 12115581
    Abstract: A rapid material development process for a powder bed fusion additive manufacturing (PBF AM) process generally utilizes a computational fluid dynamics (CFD) simulation to facilitate selection of a simulated parameter set, which can then be used in a design of experiments (DOE) to generate an orthogonal parameter space to predict an ideal parameter set. The orthogonal parameter space defined by the DOE can then be used to generate a multitude of reduced volume build samples using PBF AM with varying laser or electron beam parameters and/or feedstock chemistries. The reduced volume build samples are mechanically characterized using high throughput techniques and analyzed to provide an optimal parameter set for a 3D article or a validation sample, which provides an increased understanding of the parameters and their independent and confounding effects on defects and microstructure.
    Type: Grant
    Filed: September 22, 2023
    Date of Patent: October 15, 2024
    Assignee: The Johns Hopkins University
    Inventors: Steven M. Storck, Joseph J. Sopcisak, Christopher M. Peitsch, Salahudin M. Nimer, Zachary R Ulbig
  • Patent number: 12095085
    Abstract: The present disclosure discloses a preparation method of a tin-based lithium cobaltate precursor and use thereof. The method involves adding a cobalt salt solution, a precipitant and a complexing agent for reaction to obtain a precipitate, wherein the precipitant is a mixed solution of carbonate and stannate; calcining the precipitate; and mixing the calcined material with dioxane, ball-milling the mixture, and subjecting the ball-milled product to a heating and pressurization treatment to obtain the tin-based lithium cobaltate precursor. In the present disclosure, after carbonate and stannate are blended, the blend react with cobalt salt to form the co-precipitate of cobalt carbonate and cobalt stannate, and after calcination, a mixture of cobalt(II,III) oxide and tin dioxide is formed. By utilizing dioxane for solvent hot pressing, particles are bonded to each other, forming grain boundary channels. In addition, by doping with tin, the conductivity of the material is improved.
    Type: Grant
    Filed: November 14, 2022
    Date of Patent: September 17, 2024
    Assignees: YICHANG BRUNP CONTEMPORARY AMPEREX CO., LTD., GUANGDONG BRUNP RECYCLING TECHNOLOGY CO., LTD., HUNAN BRUNP RECYCLING TECHNOLOGY CO., LTD.
    Inventors: Haijun Yu, Yinghao Xie, Aixia Li, Xuemei Zhang, Changdong Li
  • Patent number: 11911959
    Abstract: A device (1) for the additive production of three-dimensional objects (2) by successive, layered, selective irradiation and accompanying successive, layered, selective solidification of construction material layers of a construction material (3) that can be solidified by means of an energy beam, comprising: a plurality of irradiation devices (6 and 7), which are designed to generate an energy beam, a control device (16), which is designed to generate control information controlling the operation of the irradiation devices (6 and 7) and to control the operation of the irradiation devices (6 and 7) on the basis of generated control information, wherein the control device (16) is designed to generate first control information in order to control the operation of a first irradiation device, on the basis of which the first irradiation device generates a first energy beam (4a) for the successive, layered, selective solidification of a construction material layer.
    Type: Grant
    Filed: March 9, 2018
    Date of Patent: February 27, 2024
    Assignee: Concept Laser GmbH
    Inventors: Peter Pontiller-Schymura, Felix Trutschel, Tim Döhler
  • Patent number: 11833590
    Abstract: An additive manufacturing product is provided. The additive manufacturing product includes an embedded electronic, a transition zone, and a base material. The transition zone encases the embedded electronic. The transition zone includes transition material. The base material encases the transition zone. The transition material includes an intermediate melting point that is lower than a melting point of the base material.
    Type: Grant
    Filed: May 13, 2021
    Date of Patent: December 5, 2023
    Assignee: HAMILTON SUNDSTRAND CORPORATION
    Inventors: Diana Giulietti, Alexander Madinger
  • Patent number: 11731198
    Abstract: An additive manufacturing apparatus including an energy source configured for transmitting a laser, a build plate configured to have a powder configured to be heated by the laser for additive manufacturing, at least one mirror positioned between the energy source and the build plate, the at least one mirror configured to direct the laser from the energy source to the build plate, and an optical isolator configured to reduce energy bounce back into the energy source.
    Type: Grant
    Filed: August 20, 2019
    Date of Patent: August 22, 2023
    Assignee: Rosemount Aerospace Inc.
    Inventors: Scott Wigen, Rudy Pitera, Ryan P. Chou, Greg A. Seidel, Kent A. Ramthun
  • Patent number: 11717889
    Abstract: Methods disclosed herein include using additive manufacturing to create a joint between a first metallic material and a second metallic material that is different from the first metallic material, wherein the porosity of the joint is less than about 0.1 percent by volume measured according to ASTM B-962. The additive manufacturing can be performed such that no intermetallic brittle phase forms between the first metallic material and the second metallic material.
    Type: Grant
    Filed: January 10, 2020
    Date of Patent: August 8, 2023
    Assignee: Exxon Mobil Technology and Engineering Company
    Inventors: Ning Ma, Hyun-Woo Jin, Shiun Ling
  • Patent number: 11534811
    Abstract: A process for forming extruded products using a device having a scroll face configured to apply a rotational shearing force and an axial extrusion force to the same preselected location on material wherein a combination of the rotational shearing force and the axial extrusion force upon the same location cause a portion of the material to plasticize, flow and recombine in desired configurations. This process provides for a significant number of advantages and industrial applications, including but not limited to extruding tubes used for vehicle components with 50 to 100 percent greater ductility and energy absorption over conventional extrusion technologies, while dramatically reducing manufacturing costs.
    Type: Grant
    Filed: February 12, 2021
    Date of Patent: December 27, 2022
    Assignee: Battelle Memorial Institute
    Inventors: Vineet V. Joshi, Scott A. Whalen, Curt A. Lavender, Glenn J. Grant, Md. Reza-E-Rabby, Aashish Rohatgi, Jens T. Darsell
  • Patent number: 11530492
    Abstract: An insert fixture has a base, a plurality of mounting brackets, and a plurality of separators. The plurality of separators extends vertically from the base and includes a plurality of grid portions extending the length of the insert fixture and a plurality of divider portions, which connect to the plurality of grid portions to form a plurality of individual component holders around one of the plurality of mounting brackets. Each individual component holder has two separated grid portion sections positioned on either side of the bracket. These grid portions have two divider portions which are also separated and positioned either side of the bracket at an angle relative to the two grid portions. The individual component holder forms a cell around the mounting bracket. The insert fixture may be constructed from a molybdenum alloy, lanthanum oxide and/or titanium zirconium molybdenum.
    Type: Grant
    Filed: January 14, 2020
    Date of Patent: December 20, 2022
    Assignees: ROLLS-ROYCE plc, ROLLS-ROYCE DEUTSCHLAND LTD & CO KG
    Inventors: Felix Biernot, Toma D Nikolov, Priyesh R Patel, Justin P M Tsang
  • Patent number: 11504770
    Abstract: Systems and methods are disclosed for fabricating a metal or ceramic component using a 3D printer. An entire 3D printed piece, including both the metal or ceramic component and one or more support structures, is created of a first metal or ceramic material. A sensitization layer is applied to all or part of the 3D printed piece to chemically alter portions of the first metal or ceramic material near the surface making those portions of the material more sensitive to the etching process. The etching process causes the affected material to deplete and separates the component from the support structures without requiring mechanical machining.
    Type: Grant
    Filed: February 16, 2017
    Date of Patent: November 22, 2022
    Assignees: ARIZONA BOARD OF REGENTS ON BEHALF OF ARIZONA STATE UNIVERSITY, THE PENN STATE RESEARCH FOUNDATION
    Inventors: Owen Hildreth, David Wright, Abdalla Nassar, Tim Simpson, Christopher Lefky
  • Patent number: 11498271
    Abstract: The present invention relates to a fluid supply system for a 3D printer including a fluid pressure generating device for generating a pressurized fluid flow and with a fluid heating device for heating the fluid flow, wherein the 3D printer has at least one construction chamber which is delimited by a construction chamber with respect to the surroundings of the 3D printer and is sealed in a fluid-tight manner, wherein the fluid pressure generating device, the fluid heating device and the construction chamber housing are in fluid connect ion, whereby the fluid flow can flow through the construction chamber, and wherein the fluid pressure generating device, the fluid heating device and the construction chamber housing define a closed fluid circuit for the fluid flow which is heated by the fluid heating device before entry into the construction chamber.
    Type: Grant
    Filed: September 28, 2018
    Date of Patent: November 15, 2022
    Assignee: Kumovis GmbH
    Inventors: Miriam Haerst, Stefan Leonhardt, Stefan Fischer, Sebastian Pammer
  • Patent number: 11465210
    Abstract: An additive manufacturing system for printing an article including a build plate having a build surface between an inner radius and an outer radius that may receive powder particles and a recoating assembly that may distribute the powder particles onto the build surface to form a build layer of the article. The recoating assembly includes a support jig having a first end, a second end, and a support wall extending between the first and second ends and a recoater blade coupled to the second end and extending along at least a portion of a length of the support wall. A shape of the recoater blade is such that, when the recoater blade is positioned against the build surface, an angle between the recoater blade and a tangent at each radii of the build plate is substantially constant.
    Type: Grant
    Filed: November 1, 2019
    Date of Patent: October 11, 2022
    Assignee: General Electric Company
    Inventor: Michael Robert Tucker
  • Patent number: 11325184
    Abstract: A method for producing a powder-metallurgical product, in particular a bearing element or a motor component, is provided. According to the method, a metal powder, typically with a grain size between 2 ?m and 15 ?m, is melt-metallurgically produced and agglomerated into a powder mixture having a grain size smaller than 400 ?m by organic binders and waxes. Subsequently, the agglomerated powder mixture is formed into a green body typically by way of uniaxial pressing and the formed green body thermally debindered. Finally, the debindered green body is sintered typically at temperatures of 1000° C. to 1300° C. and the sintered body reworked into the powder-metallurgical product.
    Type: Grant
    Filed: August 22, 2019
    Date of Patent: May 10, 2022
    Assignee: MAHLE International GmbH
    Inventors: Heiko Heckendorn, Lilia Kurmanaeva, Patrick Sutter, Klaus Wintrich
  • Patent number: 11325314
    Abstract: A three-dimensional printing system includes a print engine, a storage subsystem, and a controller. The print engine includes a resin vessel having a lower side with a transparent sheet, a light engine that defines a build field above the transparent sheet, and a motorized carriage for holding a support tray with a lower surface above the resin vessel. The storage subsystem is configured to store support trays. The controller is configured to: receive a build order including a plurality of incoming files individually defining a three-dimensional article to be fabricated, process and determine breakage-related risk factors for the processed files, define a build plan for at least some of the plurality of processed files based at least partly upon the determined risk factors, and operate the print engine and the storage subsystem to build and store three-dimensional articles according to the defined build plan.
    Type: Grant
    Filed: December 18, 2019
    Date of Patent: May 10, 2022
    Assignee: 3D Systems, Inc.
    Inventor: Winthrop Childers
  • Patent number: 11286208
    Abstract: Systems and methods for thermally processing composite components are provided. In one exemplary aspect, a system includes a thermal system, a mover device, and a control system. The system also includes a plurality of vessels in which one or more components may be placed. The vessels are similarly shaped and configured. A vessel containing the one or more components therein may be mounted into a chamber defined by the thermal system during thermal processing. The thermal system and vessels include features that allow components to be thermally processed, e.g., compacted, burnt-out, and densified via a melt-infiltration process, a polymer impregnation and pyrolyzing process, or a chemical vapor infiltration process. utilizing the same thermal system and common vessel design. The control system may control the thermal system and mover device to automate thermal processing of the composite components.
    Type: Grant
    Filed: August 21, 2018
    Date of Patent: March 29, 2022
    Assignee: General Electric Company
    Inventors: Aaron Todd Sellinger, Theodore Robert Grossman, Timothy P. Coons, Ryan Marcus Young, Nicholas Frederick Wendeln
  • Patent number: 11278960
    Abstract: Processes for tailoring the macroscopic shape, metallic composition, mechanical properties, and pore structure of nanoporous metal foams prepared through combustion synthesis via direct write 3D printing of metal energetic ligand precursor inks made with water and an organic thickening agent are disclosed. Such processes enable production of never before obtainable metal structures with hierarchical porosity, tailorable from the millimeter size regime to the nanometer size regime. Structures produced by these processes have numerous applications including, but not limited to, catalysts, heat exchangers, low density structural materials, biomedical implants, hydrogen storage medium, fuel cells, and batteries.
    Type: Grant
    Filed: April 11, 2019
    Date of Patent: March 22, 2022
    Assignee: Triad National Security, LLC
    Inventors: Bryce Tappan, Andrew Schmalzer, Alexander Mueller
  • Patent number: 11179807
    Abstract: Methods include directing a laser beam to a target along a scan path at a variable scan velocity and adjusting a digital modulation during movement of the laser beam along the scan path and in relation to the variable scan velocity so as to provide a fluence at the target within a predetermined fluence range along the scan path. Some methods include adjusting a width of the laser beam with a zoom beam expander. Apparatus include a laser source situated to emit a laser beam, a 3D scanner situated to receive the laser beam and to direct the laser beam along a scan path in a scanning plane at the target, and a laser source digital modulator coupled to the laser source so as to produce a fluence at the scanning plane along the scan path that is in a predetermined fluence range as the laser beam scan speed changes along the scan path.
    Type: Grant
    Filed: May 22, 2017
    Date of Patent: November 23, 2021
    Assignee: nLIGHT, Inc.
    Inventor: Robert J. Martinsen
  • Patent number: 11179894
    Abstract: In an example, a method includes forming a first layer of build material to be processed in object generation and selectively applying at least one print agent on to the first layer based on a print instruction for the first layer. Energy may be applied to the first layer to cause fusion in at least a region thereof, and at least one temperature associated with a thermal contribution of the first layer to a subsequent layer of build material to be processed in object generation may be measured. It may be determined if a temperature condition indicative of a departure from an anticipated thermal contribution of the first layer to a region of subsequent layer exists. If such a temperature condition does exist, a print instruction for applying print agent to the region of the subsequent layer based on the temperature condition may be determined.
    Type: Grant
    Filed: May 12, 2016
    Date of Patent: November 23, 2021
    Assignee: Hewlett-Packard Development Company, L.P.
    Inventors: Pol Fornos, Sergio Puigardeu Aramendia, Xavier Vilajosana
  • Patent number: 11166764
    Abstract: Systems and methods for providing assistance to a surgeon during an implant surgery are disclosed. A method includes defining areas of interest in diagnostic data of a patient and defining a screw bone type based on the surgeon's input. Post defining the areas of interest, salient points are determined for the areas of interest. Successively, an XZ angle, an XY angle, and a position entry point for a screw are determined based on the salient points of the areas of interest. Successively, a maximum screw diameter and a length of the screw are determined based on the salient points. Thereafter, the screw is identified and suggested to the surgeon for usage during the implant surgery.
    Type: Grant
    Filed: July 27, 2018
    Date of Patent: November 9, 2021
    Assignee: Carlsmed, Inc.
    Inventors: Jeffrey Roh, Justin Esterberg
  • Patent number: 11148207
    Abstract: A laser shock peening method for an additive manufactured component of a double-phase titanium alloy is provided. First, a three-dimensional digital model of a complex component is obtained, and the model is divided into a plurality of slices; a forming direction of a formed part in an additive manufacturing process is determined according to a stress direction of the additive manufactured component in an engineering application; then, the component of the double-phase titanium alloy is formed and manufactured by selective laser melting, and orientations of a C-axis of an ? phase is allowed to be consistent through adjustment and control; and finally, laser shock peening is performed on all outer surfaces of the high-performance additive manufactured component of the double-phase titanium alloy by inducing a high-intensity shock wave to act in an acting direction which forms an angle in a predetermined range with the C-axis of the ? phase.
    Type: Grant
    Filed: September 18, 2020
    Date of Patent: October 19, 2021
    Assignee: JIANGSU UNIVERSITY
    Inventors: Kaiyu Luo, Haifei Lu, Jinzhong Lu, Xiancheng Zhang, Guang Yang
  • Patent number: 11097472
    Abstract: At least one agent distributor may be to selectively deliver coalescing agent onto portions of a layer of build material at a first density and at a second density lower than the first density. A controller may be to control the at least one agent distributor to selectively deliver the coalescing agent at the first and second densities onto respective first and second portions of the layer in respective first and second patterns derived from data representing the three-dimensional object to be generated, so that when energy is applied to the layer the build material may coalesce and solidify to form a slice of the three-dimensional object in accordance with the first pattern. The second portion may be in proximity to a boundary of the first portion. Presence of the coalescing agent in the second portion may be to prevent at least some heat from flowing away from the first portion when the energy is applied.
    Type: Grant
    Filed: July 30, 2019
    Date of Patent: August 24, 2021
    Assignee: Hewlett-Packard Development Company, L.P.
    Inventors: Bernardo A. Gutierrez, Jacob T. Wright, Michael A. Novick
  • Patent number: 11072123
    Abstract: In one example, an additive manufacturing process includes: making an object slice by slice, including dispensing a first quantity of each of multiple liquid functional agents on to a layer of fusable build material and then irradiating the layer of build material; while making the object, identifying a deviant region in a slice; and dispensing a second quantity different from the first quantity of at least one of the functional agents into a location corresponding to the deviant region.
    Type: Grant
    Filed: January 18, 2017
    Date of Patent: July 27, 2021
    Assignee: Hewlett-Packard Development Company, L.P.
    Inventors: Aja Hartman, Lihua Zhao
  • Patent number: 11059224
    Abstract: Plant (1) for additively manufacturing of three-dimensional objects (2), comprising at least two apparatuses (3, 4) for additively manufacturing of three-dimensional objects (2) by means of successive layerwise selective irradiation and consolidation of layers of a build material (5) which can be consolidated by means of an energy beam (6-9), wherein a separate beam generating unit (10) configured to generate at least one energy beam (6-9) that is guidable to at least one of the apparatuses (3, 4).
    Type: Grant
    Filed: May 23, 2018
    Date of Patent: July 13, 2021
    Assignee: CONCEPT LASER GMBH
    Inventors: Jens Stammberger, Tanja Kroher, Andreas Ullrich, Daniel Winiarski
  • Patent number: 10994337
    Abstract: An intelligent feed forward model to control additive manufacturing (AM) laser powder bed fusion process and reduce spattering whereby defects are eliminated by controlling the laser power and reducing spattering through a computer model. This application describes using a proportional integral derivative (PID) controller to create a power map that reduces spattering.
    Type: Grant
    Filed: December 12, 2018
    Date of Patent: May 4, 2021
    Assignee: Lawrence Livermore National Security, LLC
    Inventors: Saad A. Khairallah, Gabe Guss, Wayne E. King, Sonny S. Ly, Manyalibo Joseph Matthews, Alexander M. Rubenchik
  • Patent number: 10898971
    Abstract: A three-dimensional deposition device and a three-dimensional deposition method used to highly accurately manufacture a three-dimensional object are provided. A three-dimensional deposition device for forming a three-dimensional shape by depositing a formed layer on a base unit includes: a powder supply unit which supplies a powder material; a light irradiation unit which irradiates the powder material with a light beam so that at least a part of the powder material irradiated with the light beam is sintered or melted and solidified to form the formed layer; a heating unit which selectively heats an area having passed through a position irradiated with the light beam in the base unit or the formed layer or an area not having passed through the position irradiated with the light beam; and a control device which controls operations of the powder supply unit, the light irradiation unit, and the heating unit.
    Type: Grant
    Filed: March 20, 2015
    Date of Patent: January 26, 2021
    Assignee: MITSUBISHI HEAVY INDUSTRIES, LTD.
    Inventor: Hitoshi Yoshimura
  • Patent number: 10875093
    Abstract: Additive manufacturing includes successively forming a plurality of layers on a support. Depositing a layer from the plurality of layers includes dispensing first particles, selectively dispensing second particles in selected regions corresponding to a surface of the object, and fusing at least a portion of the layer. The layer has the first particles throughout and the second particles in the selected regions. Alternatively or in addition, forming the plurality of layers includes depositing multiple groups of layers. Depositing a group of layers includes, for each layer in the group of layers dispensing a feed material to provide the layer, and after dispensing the feed material and before dispensing a subsequent layer fusing a selected portion of the layer. After all layers in the group of layers are dispensed, a volume of the group of layers that extends through all the layers in the group of layers is fused.
    Type: Grant
    Filed: July 15, 2016
    Date of Patent: December 29, 2020
    Assignee: Applied Materials, Inc.
    Inventors: Hou T. Ng, Nag B. Patibandla, Ajey M. Joshi, Bharath Swaminathan, Ashavani Kumar, Eric Ng, Bernard Frey, Kasiraman Krishnan
  • Patent number: 10821670
    Abstract: A method for additive manufacturing of a three-dimensional object (6) by successive, selective layer-by-layer solidification of layers of a construction material (9) by at least one energy beam, wherein the successive, selective solidification of the construction material (9) is carried out due to a data record describing the three-dimensional object to be additively manufactured (6), wherein construction material sections provided for sintering and/or melting on or melting through are heated in a temperature range lying below the solidification temperature of the construction material (9), wherein the heating of the construction material section(s) is carried out by at least one heating beam (17) either surrounding at least one main beam (18) provided for melting on or melting through in sections or going ahead or following the main beam (18), wherein the main beam (18) and the heating beam (17) are together guided synchronously along the surface of the construction material (9).
    Type: Grant
    Filed: November 14, 2017
    Date of Patent: November 3, 2020
    Assignee: Concept Laser GmbH
    Inventors: Tim Döhler, Peter Pontiller-Schymura, Alexandra Popp
  • Patent number: 10780634
    Abstract: A nozzle according to one embodiment includes a nozzle unit and a guide surface. A first passage, a second passage, and the guide surface are provided to the nozzle unit. The first passage has a first open end. The second passage has a second open end, and a section that is positioned upstream of the second open end and that extends in a second direction. The guide surface has an edge in a first direction. The guide surface is exposed on the outer side at the edge, is along a third direction at the edge, the third direction being a direction becoming more distanced from an axis than the second direction does, as the third direction is extended further toward the first direction. A flow of fluid ejected from the second open end follows the guide surface, and becomes separated from the nozzle unit at the edge.
    Type: Grant
    Filed: September 17, 2018
    Date of Patent: September 22, 2020
    Assignees: Technology Research Association for Future Additive Manufacturing, Kabushiki Kaisha Toshiba, Toshiba Kikai Kabushiki Kaisha
    Inventors: Hiroshi Ohno, Satoshi Tsuno, Mitsuo Sasaki, Tomohiko Yamada, Yasutomo Shiomi, Shimpei Fujimaki
  • Patent number: 10695983
    Abstract: A device for the layer-wise additive production of a complex three-dimensional component has a measuring mechanism for continuously monitoring quality indicators during the production of the component, wherein the measuring mechanism and a bed with a material powder are surrounded, at least in regions, by a processing cell filled with a protective gas atmosphere and the material powder of an uppermost layer can be melted in a locally limited manner in a melting zone by means of at least one laser. The measuring mechanism has the at least one laser and at least one optical sensor for the priority detection of the quality indicators in the region of the melting zone, in particular by means of Raman spectroscopy. Consequently, any construction errors in the component can be recognised, evaluated and, if necessary, corrected in a resource-saving manner without delay.
    Type: Grant
    Filed: May 23, 2016
    Date of Patent: June 30, 2020
    Assignee: APWORKS GmbH
    Inventors: Franz Engel, Andreas Nick, Wolfgang Rehm, Christian Weimer
  • Patent number: 10682702
    Abstract: A method for using a build plate including a reusable supporting platform for additive manufacturing of a component is disclosed. The method may include additive manufacturing the reusable supporting platform on a top surface of a base of the build plate, and additive manufacturing a first component on the second surface of the reusable supporting platform. The method may also include separating the first component from the build plate at the second surface of the reusable supporting platform, thereby exposing a new surface of the body of the reusable supporting platform. Additionally, the method may include additive manufacturing at least a second component on the new surface of the reusable supporting platform. The reusable supporting platform may include a body including a first surface coupled to the top surface of the base of the build plate, and a second surface configured to support a component to be formed by additive manufacturing and for separation of the component from the build plate.
    Type: Grant
    Filed: January 31, 2017
    Date of Patent: June 16, 2020
    Assignee: General Electric Company
    Inventors: Juan Vicente Haro Gonzalez, Jan Vladimir Schwerdtfeger
  • Patent number: 10683568
    Abstract: An object of this heat-resistant sintered material and a production method therefor is to obtain a heat-resistant sintered material having excellent oxidation resistance, high-temperature wear resistance and salt damage resistance. This heat-resistant sintered material has a composition containing, in mass % values, Cr: 25 to 50%, Ni: 2 to 25% and P: 0.2 to 1.2%, with the remainder being Fe and unavoidable impurities, and has a structure including an Fe—Cr matrix, and a hard phase composed of Cr—Fe alloy particles dispersed within the Fe—Cr matrix, wherein the Cr content of the Fe—Cr matrix is from 24 to 41 mass %, the Cr content of the hard phase is from 30 to 61 mass %, and the effective porosity is 2% or less.
    Type: Grant
    Filed: March 25, 2016
    Date of Patent: June 16, 2020
    Assignee: Diamet Corporation
    Inventors: Kenichi Kato, Tatsuki Mizuno, Masahisa Miyahara
  • Patent number: 10662786
    Abstract: An engine component is generally provided for a gas turbine engine generating hot combustion gas flow. In one embodiment, the engine the engine component includes a substrate having a hot surface facing the hot combustion gas flow and a cooling surface facing a cooling fluid flow. The substrate defines a film hole extending through the substrate and having an inlet provided on the cooling surface, an outlet provided on the hot surface, and a passage connecting the inlet and the outlet. The passage defines a diffusion section having a pair of side passage walls extending to the outlet on the hot surface, with each of the side passage walls within the diffusion section having a surface roughness (Ra) of about 4 mils to about 7 mils. Methods are also provided for forming a film hole in a CMC substrate.
    Type: Grant
    Filed: January 12, 2016
    Date of Patent: May 26, 2020
    Assignee: General Electric Company
    Inventors: Anquan Wang, Wilbur Douglas Scheidt, Jeffrey Lehmkuhl
  • Patent number: 10625338
    Abstract: Additive manufacturing of an object includes dispensing a plurality of successive layers of powder over a top surface of a platform, fusing an object region in each of the plurality of successive layers to form the object, and fusing a brace region in a particular layer from the plurality of layers to form a brace structure to inhibit lateral motion of the powder. The brace structure is spaced apart from the particular object region by a gap of unfused powder.
    Type: Grant
    Filed: July 15, 2016
    Date of Patent: April 21, 2020
    Assignee: Applied Materials, Inc.
    Inventors: Hou T. Ng, Nag B. Patibandla, Ajey M. Joshi, Bharath Swaminathan, Ashavani Kumar, Eric Ng, Bernard Frey, Kasiraman Krishnan
  • Patent number: 10458006
    Abstract: A laser cladding or plasma transferred arc overlay welding process may be used advantageously to apply and to control the material properties of a coating designed for protecting the substrate against wear, corrosion and oxidation at elevated temperature. Furthermore, a laser cladding or plasma transferred arc overlay welding process may be used to apply the coating alloy materials in applications where traditional thermal spray or weld-applied coatings are not practical. By using these welding methods very good bonding is achieved by fusion during welding. At the same time the properties of the clad layer is preserved by the limited dilution typical of these two welding methods compared traditional overlay welding, by e.g. Gas Tungsten Arc Welding and the like.
    Type: Grant
    Filed: March 17, 2016
    Date of Patent: October 29, 2019
    Assignee: HÖGANÄS AB (PUBL)
    Inventor: Sven Bengtsson
  • Patent number: 10444068
    Abstract: A calibration device (30) for an apparatus (1) for layerwise production of a three-dimensional object (2) by layerwise solidification of building material (10) at the locations corresponding to the cross section of the object to be produced in the respective layer by means of at least two energy beams (14a, 14b) includes a housing (31) and a sensor (32) which is arranged in the housing. The sensor serves to receive the at least two energy beams and to output an output signal as a function of the intensity of the energy beams. The housing has at least two through-openings (34a, 34b) for transmitting the at least two energy beams, which are arranged so that their central axes intersect on a surface of the sensor.
    Type: Grant
    Filed: June 27, 2014
    Date of Patent: October 15, 2019
    Assignee: EOS GMBH ELECTRO OPTICAL SYSTEMS
    Inventor: Jochen Philippi
  • Patent number: 10343330
    Abstract: A system for additively manufacturing a composite part is disclosed. The system comprises a delivery guide, movable relative to a surface. The delivery guide is configured to deposit at least a segment of a continuous flexible line along a print path. The print path is stationary relative to the surface. The continuous flexible line comprises a non-resin component and a thermosetting-epoxy-resin component that is partially cured. The system also comprises a feed mechanism, configured to push the continuous flexible line through the delivery guide. The system further comprises a cooling system, configured to maintain the thermosetting-epoxy-resin component of the continuous flexible line below a threshold temperature prior to depositing the segment of the continuous flexible along the print path via the delivery guide.
    Type: Grant
    Filed: November 3, 2015
    Date of Patent: July 9, 2019
    Assignee: The Boeing Company
    Inventors: Nick S. Evans, Faraón Torres, Ryan G. Ziegler, Samuel F. Harrison, Ciro J. Grijalva, III, Hayden S. Osborn
  • Patent number: 10256054
    Abstract: A method is disclosed for improving the production of electrical switch contacts, in particular for vacuum tubes. In the method, an electrical or electromagnetic field assists and/or effects a sintering process. In the method, the sintering process takes place on a metallic carrier, and via the method, semi-finished contact elements for electrical switch contacts, contact elements for electrical switch contacts, and/or electrical switch contacts, in particular for vacuum tubes, are produced.
    Type: Grant
    Filed: June 4, 2014
    Date of Patent: April 9, 2019
    Assignee: SIEMENS AKTIENGESELLSCHAFT
    Inventors: Dirk Pohle, Wolfgang Rossner, Klaus Schachtschneider, Carsten Schuh
  • Patent number: 10232439
    Abstract: A method of controlling an additive manufacturing process in which a directed energy source is used to selectively fuse powdered material to form a workpiece, in the presence of a gas flow, the method including: using at least one gas flow sensor to generate at least one gas flow measurement; and controlling at least one aspect of the additive manufacturing process in response to the at least one gas flow measurement.
    Type: Grant
    Filed: November 20, 2015
    Date of Patent: March 19, 2019
    Assignee: General Electric Company
    Inventors: Scott Alan Gold, James Harding Shealy, Jonathan William Ortner
  • Patent number: 10040122
    Abstract: Embodiments of a methods for producing gas turbine engine rotors and other powdered metal articles having shaped internal cavities are provided. In one embodiment, the method includes consolidating a powdered metal body utilizing a hot isostatic pressing process to produce a rotor preform in which elongated sacrificial tubes are embedded. Acid or another solvent is directed into solvent inlet channels provided in the elongated sacrificial tubes to chemically dissolving the elongated sacrificial tubes and create shaped cavities within the rotor preform. The rotor preform is subject to further processing, such as machining, prior to or after chemical dissolution of the elongated sacrificial tubes to produce the completed gas turbine engine rotor.
    Type: Grant
    Filed: September 22, 2014
    Date of Patent: August 7, 2018
    Assignee: HONEYWELL INTERNATIONAL INC.
    Inventors: Deanna Pinar Chase, Amandine Miner, Harry Lester Kington, Anthony Martinez
  • Patent number: 9939015
    Abstract: Provided is a sintered bearing (1) including an inner layer (2) and an outer layer (3) formed by integral molding, the sintered bearing (1) having a bearing surface (A) formed on an inner peripheral surface (2a) of an inner layer (2). The inner layer (2) is made of sintered metal containing Fe and a hardness increasing element (such as Ni or Mo). The outer layer (3) is made of sintered metal containing Fe and no hardness increasing element. A concentration gradient of the hardness increasing element is present at an interface between the inner layer (2) and the outer layer (3).
    Type: Grant
    Filed: August 15, 2016
    Date of Patent: April 10, 2018
    Assignee: NTN CORPORATION
    Inventors: Toshihiko Mouri, Noriyoshi Yoshizuka, Yousuke Sugai, Fuminori Satoji
  • Patent number: 9919362
    Abstract: The procedure for the mechanical alloying of metals comprises grinding at least a metal inside a grinding mill together with at least a control agent to obtain a powdered ground product, wherein: —the metal is selected from the list comprising: titanium, zirconium, hafnium, vanadium, niobium, tantalum, chromium, molybdenum, tungsten; and—the control agent is selected from the list comprising: magnesium, calcium and rare earths.
    Type: Grant
    Filed: March 28, 2014
    Date of Patent: March 20, 2018
    Assignee: K4SINT S.R.L.
    Inventors: Luca Girardini, Mario Zadra
  • Patent number: 9707623
    Abstract: A multiphase composite system is made by binding hard particles, such as TiC particles, of various sizes with a mixture of titanium powder and aluminum, nickel, and titanium in a master alloy or as elemental materials to produce a composite system that has advantageous energy absorbing characteristics. The multiple phases of this composite system include an aggregate phase of hard particles bound with a matrix phase. The matrix phase has at least two phases with varying amounts of aluminum, nickel, and titanium. The matrix phase forms a bond with the hard particles and has varying degrees of hard and ductile phases. The composite system may be used alone or bonded to other materials such as bodies of titanium or ceramic in the manufacture of ballistic armor tiles.
    Type: Grant
    Filed: November 18, 2013
    Date of Patent: July 18, 2017
    Inventor: Robert G. Lee
  • Patent number: 9403160
    Abstract: The invention relates to a method for producing micro-nano combined active systems in which nanoparticles of a first component are bonded to microparticles of a second component, comprising the following steps: (a) producing a low-ligand colloidal suspension containing nanoparticles of the first component, (b) adding microparticles to the colloidal suspension containing the nanoparticles or adding the colloidal suspension containing the nanoparticles to a dispersion containing the microparticles and intensively mixing so that the nanoparticles adsorb onto the microparticles, (c) separating the microparticles and the nanoparticles bonded thereto from the liquid and drying the microparticles and the nanoparticles bonded thereto.
    Type: Grant
    Filed: December 16, 2011
    Date of Patent: August 2, 2016
    Assignee: Particular GmbH
    Inventors: Stephan Barcikowski, Philipp Wagener, Andreas Schwenke
  • Patent number: 9364886
    Abstract: The invention relates to a method for manufacturing a dog ring gear, each dog being made up of a front portion and a rear portion, the method including the following steps: forming, by means of compression and sintering, a ring gear with dog preforms extending on all or part of the periphery thereof; and calibrating the sintered ring gear in a die including a front die half and a rear die half intended for engaging at the junction between the front and rear portions of the dogs, the thickness (A) of a rear portion (BP) of each preform, in the original plane of the dogs, being greater than the narrowest section (S1) of a groove formed in the rear die half and smaller than the thickest section (S2) of the groove, in the plane.
    Type: Grant
    Filed: November 16, 2010
    Date of Patent: June 14, 2016
    Assignee: FEDERAL MOGUL SINTERTECH
    Inventors: Vincent Bonnefoy, Jean-Luc Ebroussard
  • Publication number: 20150135897
    Abstract: The disclosure relates to the manufacture of metal articles, more specifically the manufacture of metal articles by additive manufacturing techniques, and in particular to the manufacture of metal articles by an additive manufacturing technique that may involve the selective melting or sintering of a metal powder. Examples of such techniques may include selective laser melting (SLM), selective laser sintering (SLS) and techniques that use an electron beam rather than a laser. Exemplary embodiments include a method of manufacture of an article including selective melting and/or sintering of a powder including an alloy containing aluminium, wherein the alloy contains bismuth.
    Type: Application
    Filed: May 28, 2013
    Publication date: May 21, 2015
    Inventors: Christopher John Sutcliffe, Peter Fox
  • Publication number: 20150132173
    Abstract: An additive manufacturing apparatus (10) and process including selectively heating a processing plane of a bed of powdered material (14) that includes a powdered metal material (14?), and may also include a powdered flux material (14?). The heating may be accomplished by directing an energy beam, such as a laser beam (20), toward a processing plane (27) of the bed. One or more masking elements (61, 62) are disposed between a source (18) of the beam and the processing plane; and the masking elements are variable to change a beam pattern at the processing plane according to a predetermined shape of a component (22) to be formed or repaired.
    Type: Application
    Filed: November 5, 2014
    Publication date: May 14, 2015
    Inventors: Gerald J. Bruck, Ahmed Kamel
  • Publication number: 20150125333
    Abstract: A system and process of additive manufacturing using a fluidized bed of powdered material (14) including powdered metal material (14?) and powdered flux material (14?)? including heating the powdered material with an energy beam (20) delivered from a location below a top surface (25) of the powdered material. The powdered bed is fluidized by introduction of an inert or non-inert gas into a chamber (12). As the powdered material is heated, melted and solidified, a layer of slag (32) forms over a deposited metal (38) and is then removed so that fluidized powdered settling on a previously deposited area (34) can be heated, melted and solidified to build up a component (22).
    Type: Application
    Filed: November 5, 2013
    Publication date: May 7, 2015
    Inventors: Gerald J. Bruck, Ahmed Kamel
  • Publication number: 20150104344
    Abstract: Methods and systems are provided for using optical interferometry in the context of material modification processes such as surgical laser or welding applications. An imaging optical source that produces imaging light. A feedback controller controls at least one processing parameter of the material modification process based on an interferometry output generated using the imaging light. A method of processing interferograms is provided based on homodyne filtering. A method of generating a record of a material modification process using an interferometry output is provided.
    Type: Application
    Filed: August 25, 2014
    Publication date: April 16, 2015
    Inventors: Paul J.L. Webster, James M. Fraser, Victor X.D. Yang
  • Patent number: 8992828
    Abstract: A method for manufacturing a high ductility Ti-, Ti-alloy or NiTi-foam, meaning a compression strain higher than 10%, includes: preparing a powder suspension of a Ti-, NiTi- or Ti-alloy powder, bringing the said powder suspension into a desired form by gelcasting to form a green artifact. The method also includes a calcination step wherein the green artifact is calcined, and sintering the artifact. The calcination step includes a slow heating step wherein said green artifact is heated at a rate lower or equal to 20° C./hour to a temperature between 400° C. and 600° C. and the Ti-, NiTi- or Ti-alloy powder has a particle size less than 100 ?m. A high ductility Ti-, Ti-alloy or NiTi foam, with a compression higher than 10%, with a theoretical density less than 30%, pore size (cell size) between 50 to 1000 ?m can be obtained with such a method.
    Type: Grant
    Filed: June 7, 2006
    Date of Patent: March 31, 2015
    Assignee: Vlaamse Instelling Voor Technologisch Onderzoek (VITO)
    Inventors: Steven Mullens, Ivo Thijs, Jozef Cooymans, Jan Luyten
  • Publication number: 20150028548
    Abstract: A tool holder with a main part, a deformable receiving portion for clamping a tool, and at least one blocking element which is designed to engage into a corresponding counter element on the tool in order to prevent the tool from moving axially out of the tool holder. The at least one blocking element is integrally formed with the receiving portion. A clamping system having such a tool holder and a method for producing a receiving portion for such a tool holder are also described.
    Type: Application
    Filed: December 20, 2012
    Publication date: January 29, 2015
    Inventor: Franz Haimer
  • Publication number: 20150017051
    Abstract: A method of speedily forming dental implant auxiliary devices comprises a tooth mold reproducing step, a processing drawing setting step, and a formation step. In the tooth mold producing step, a buccal mold is made according to a shape of an oral cavity; in the processing drawing setting step, an implant marked object is designed in respect to the buccal mold for setting a three-dimensional processing drawing of a dental implant auxiliary device; and in the formation step, the drawing is input to a laser sintering and forming system, so that the system directly and quickly forms and shapes the implant fixing device according to the three-dimensional drawing. The method reduces the manufacture time effectively and increases the manufacture precision, which allows the metal implant to be correctly implanted in surgery for enhancing a success rate of the surgery and reducing manufacture costs.
    Type: Application
    Filed: July 11, 2013
    Publication date: January 15, 2015
    Inventors: KOU-TSAIR SU, YU-JUNG SU